Surgical system including powered rotary-type handpiece

Abstract

A surgical system which may include a controller, a data entry device, a powered surgical handpiece and a surgical tool adapted to couple to the surgical handpiece. The surgical handpiece can include motor direction control and feedback, safety stop features, stimulation and nerve integrity monitoring, a tool connector assembly configured to retain a variety of surgical tools and optional navigation and/or electric ratcheting features.

1 - 12 . (canceled) 
     
     
         13 . A surgical handpiece, comprising:
 an electrical motor configured to receive a motor current;   a driveshaft extending along an axis defined through the handpiece, the driveshaft rotatable about the axis by the electrical motor;   a surgical tool connected to the surgical handpiece, the surgical tool coupled to and rotatable by the driveshaft; and   a controller disposed within the surgical handpiece, the controller including a data entry device and a display screen, the controller programmed to integrate the motor current, wherein the display screen of the controller is configured to display a real-time torque value applied by the surgical handpiece based on the motor current and to react to a rate of change of the torque value over time based on a change in the motor current.   
     
     
         14 . The surgical handpiece according to  claim 13 , wherein the controller is configured to limit the rate of change of the torque value over time based on a motor current feedback. 
     
     
         15 . The surgical handpiece according to  claim 13 , wherein the controller is configured to detect a failure of the surgical tool based on the rate of change of the torque value over time or a temperature. 
     
     
         16 . The surgical handpiece according to  claim 15 , wherein, upon a detection of a failure, the controller is configured to stop the electrical motor or control the motor current delivered to the electrical motor. 
     
     
         17 . The surgical handpiece according to  claim 14 , wherein the controller is configured to detect a failure of a bone based on the rate of change of the torque value over time. 
     
     
         18 . The surgical handpiece according to  claim 14 , wherein the controller is configured to detect a screw or plate based on the rate of change of the torque value over time. 
     
     
         19 . The surgical handpiece according to  claim 13 , further comprising a ratchet operatively associated with the driveshaft. 
     
     
         20 . The surgical handpiece according to  claim 13 , further comprising a stimulator assembly operably coupled to the driveshaft and configured to apply stimulation energy thereto, wherein the stimulator assembly is configured to stimulate the surgical tool via stimulation of the driveshaft. 
     
     
         21 . The surgical handpiece according to  claim 20 , further comprising a contact subassembly configured to transmit the stimulation energy to the driveshaft. 
     
     
         22 . The surgical handpiece according to  claim 21 , wherein the stimulation energy is electrical stimulation energy and provides nerve integrity monitoring (NIM). 
     
     
         23 . The surgical handpiece according to  claim 20 , wherein the stimulator assembly includes an interface pin disposed within a housing of the surgical handpiece, the interface pin electrically coupled to the contact subassembly. 
     
     
         24 . The surgical handpiece according to  claim 23 , wherein the contact subassembly includes a contact operably coupled to the driveshaft. 
     
     
         25 . The surgical handpiece according to  claim 23 , wherein the contact subassembly includes a slip ring retained by a contact housing of the contact subassembly. 
     
     
         26 . The surgical handpiece according to  claim 23 , wherein the contact subassembly includes a solder cup for operably coupling the interface pin to wiring. 
     
     
         27 . The surgical handpiece according to  claim 14 , wherein the controller is programmed to estimate the temperature of the electrical motor. 
     
     
         28 . The surgical handpiece according to  claim 27 , wherein the controller is programmed to estimate a temperature of the electrical motor via an algorithm that estimates the temperature of the electrical motor by integrating the square of the motor current over time. 
     
     
         29 . The surgical handpiece according to  claim 28 , wherein the algorithm is programmed to compensate for current losses due to changes in a resistance of motor windings disposed within the electrical motor by using the temperature estimate of the electrical motor.